The customer was UME (National Metrology Institute of Turkiye), a research and development institute operating under the umbrella of TUBITAK (The Scientific and Technological Research Council of Turkiye), located in Kocaeli, Turkiye. Their primary mission is to validate all measurements conducted within Turkiye and ensure their international comparability. UME continuously develops and refines measurement techniques to enhance the precision of industrial and commercial measurements. To fulfill this mission, they have established the National Metrology System, which contributes to improving the quality of Turkish products and strengthening Turkiye’s scientific and technological infrastructure. UME also develops and maintains Turkish Measurement Reference Standards and ensures their traceability to the International Measurement System.
To support the needs of their Force Laboratory, UME required a high-capacity, cutting-edge solution with extremely high accuracy and precision. The specified system was a 50kN–3MN Force Standard Machine equipped with a Reference Force Transducer. As no domestic manufacturer in Turkiye was producing such advanced equipment, UME began seeking mechanical and automation solution providers capable of developing it.
The team was selected for the automation development.
The calibrator’s mechanical structure was designed as a tripod, incorporating two distinct motor systems-one to position the transducers and the other to drive the pressure piston. During operation, the automation system was responsible for continuously and synchronously measuring both the reference and test transducers, while maintaining a fully automated workflow.
The core challenge was achieving accuracy. The pressure piston applied forces up to ~3 MN. Meeting the ±4×10-4 accuracy requirement meant keeping the margin of error within ±120 kg-force, an extremely narrow tolerance. Failing to achieve this level of accuracy would have meant failing to deliver the project.
The customer also required custom-developed computer software for comprehensive control of the calibrator. This included managing calibration procedures, enabling manual operation, performing full calibrations, storing data, and generating “National Calibration Certificates.”
The final solution was a fully integrated automation system combining the calibrator hardware and dedicated software. The computer software communicated with high-precision transducer readers to capture and log force readings. It also controlled all sensors and motors in real time via a Schneider PLC (Programmable Logic Controller) and DC servo motor controllers. To further enhance reliability and long-term stability, a first-of-a-kind artificial intelligence (AI) component was implemented to learn the system and adapt to changes on the fly. This AI learned the calibrator's behavior over time and adapted its controls accordingly. It autonomously managed the measurement sequences, detected anomalies, and repeated calibration cycles as needed. Upon successful validation of all parameters, it automatically generated a printed National Calibration Certificate. The complete calibration cycle required 28 hours of uninterrupted, human-free operation.
While the software managed data and process logic, the hardware automation maintained the required accuracy throughout operation.
The development of the software and firmware took one year and resulted in a seamlessly functioning system. Over 30 international intercomparisons were performed with other national calibration institutes (e.g., Germany). The system not only met the required accuracy of ±4×10-4 but surpassed it, achieving a remarkable ±1×10-4 and stabilizing force application within ±30 kg-force.
Even at a 5kN force level (1/10 of the system’s minimum calibration range), the calibrator achieved the required accuracy of ±4×10-4, despite being designed for forces up to 3MN.
Since 2002, UME has used this calibrator as Turkiye’s National 50kN–3MN Force Standard Machine with Reference Force Transducer.
During the system’s development, two PhD thesis topics were generated based on research conducted in the process: “Zero-Shifting Error of Transducers under Long-Term Pressure” and “Variations in Measurement Results after Consecutive Calibrations”.
More detailed information about the Force Laboratory is available here: www.ume.tubitak.gov.tr/en/mechanical-group-laboratories/force-laboratory
This calibrator, developed domestically in Turkiye at one-fifth the cost of foreign competitors, delivers four times the accuracy.
Customer
Project
Solution
Conclusion
Result
